Surface & Panel Q3 2018

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& U N I T I N G M AT E R I A L S , T E C H N O L O G Y A N D D E S I G N

TRANSFORMING SPACE TO THE MAX FINEST GAME TABLES FEATURE FINE SURFACES UNITY THROUGH DIVERSIFICATION AT ILCAM RIDING THE WAVE AT STEVENS INDUSTRIES HARDWARE INNOVATIONS OFFER BETTER SOLUTIONS COUNTERTOPS: PORCELAIN MAKES A MOVE

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No matter how you look at it, has you covered.

Customers, designers, manufacturers and management finally agree on something:

Premeer performs! ÂŽ

Many people are involved in the development of decorative panels and surfaces. Designers must appeal to customers and meet their performance demands. Manufacturers are concerned with production efficiency and productivity. Of course, management has a laser focus on the bottom line.

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MANAGEMENT

Regardless of which perspective is yours, Premeer OPP decorative overlay by Interprint offers you exciting new advantages!

Premeer is designed and manufactured by Interprint. Premeer.com Interprint, Inc. 101 Central Berkshire Boulevard, Pittsfield, MA 01201 (413) 443-4733 Interprint.com

F R O M

T H E

P U B L I S H E R

Live Smart Ingvar Kamprad, the visionary founder of IKEA, died in January at age 91. While many of us connect Kamprad to the iconic IKEA brand, few of us know that he also was instrumental in transforming the housing industry.

Kamprad, along with the international construction firm Skanska, created a new way of producing living spaces for the masses. Rather than simply find out how efficiently homes could be built, Kamprad and the president of Skanska decided to create homes for a large and overlooked segment of the housing market— the multitudes of average Swedish citizens.

“The vision is to create homes for the many,” he said. “People should be able to pay for their homes themselves. It’s much better than subsidies in the long run. Our challenge is to keep the price low.”

And they wondered: What could a nurse, sales clerk, single parent or student afford to pay to own their own home? In the end, their research found that a single nurse with a child could spend $380 per month.

That number became the standard on which all other decisions were made.

Employing manufacturing technologies, automation and production systems that made IKEA famous, “BoKlok” homes were born. Boklok, Swedish for “living smart,” became an instant success. Boklok homes are built in a controlled indoor environment, designed with large windows and well-thought-out floor plans.

The homes are stylish and energy efficient, but they are considered cozy, not flashy. Each home includes IKEA furnishings, right down to the hangers in the closet.

Boklok homes are sold at IKEA stores in Sweden, Norway and Finland. Demand is so high that prospects are selected from a lottery. About 1,200 Boklok homes are built per year, and capacity is being increased by more than 50 percent due to demand. Since its inception, the joint venture between IKEA and Skanska has produced more than 11,000 homes.

Thinking of Kamprad’s legacy brings to mind another visionary who made enormous contributions to our industry. While not as widely known as Kamprad, Marshall Erdman may be considered the father of panel processing and was one of the earliest producers of prefabricated buildings.

As a contemporary of Frank Lloyd Wright, Erdman built many of Wright’s buildings. Erdman was well known for producing prefabricated medical offices, complete with “exam-rooms-in-a-box” delivered with cabinetry, nearly complete and ready to use. Erdman launched Techline (acquired by Stevens Industries), one of the first high-end panel processed residential and office furniture producers, which is still widely revered today.

I have wonderful memories of escorting Erdman to the press room at the LIGNA fair in Hannover, where we would visit for hours. I had dinner with him several times and will always remember the experience. His creativity and passion for the industry have always been a great inspiration for me. I was fortunate to have known him. Marshall died in 1995.

Ingvar Kamprad and Marshall Erdman were pioneers. Both are gone, but their disciples live on.

“Thinking of Kamprad’s legacy brings to mind another visionary who made enormous contributions to our industry. While not as widely known as Kamprad, Marshall Erdman may be considered the father of panel processing and was one of the earliest producers of prefabricated buildings.”

John Aufderhaar | President | Bedford Falls Communications | john@bedfordfallsmedia.com | 920-206-1766 surface&panel

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32 6 Digital Printing Symposium at IWF 2018 The symposium will focus on digital printing opportunities available and introduce attendees to leading manufacturers in the digital arena.

10 Transforming Space to the Max Resource Furniture has become a giant among high-end, multifunctional furniture retailers.

18 World Leader in Surfacing Shares What’s Next in Residential Interiors To learn what's new at Wilsonart and what's planned, Surface & Panel interviewed President and Chief Executive Officer Timothy J. O'Brien. [ D E P A R T M E N T S ]

3 From the Publisher 64 From the Editor 66 Advertiser Index

20 Finest Game Tables Feature Fine Surfaces 11 Ravens makes some of the finest, most expensive game tables in the world. Not surprisingly, materials and style matter when you’re playing in such rarified air.

24 Unity Through Diversification ILCAM creates strategic internal supply chain to become one of world’s leading door makers.

32 Get Ready for the MT&D Symposium Change, disruption and the opportunities they bring will be key themes during the 2018 Material, Technology & Design Symposium @ CPA Fall Meeting, set for Sept. 23-25 in Nashville.

P U B L IS H E R

John Aufderhaar President | Bedford Falls Communications 302 N. 3rd Street, Watertown, WI 53094 PH: 920-206-1766 john@bedfordfallsmedia.com

38 Riding the Wave Onshoring, versatility, TFL growth help generate surge at Stevens Industries.

CONTENT

Scott W. Angus Editorial Director | Bedford Falls Communications 302 N. 3rd Street, Watertown, WI 53094 PH: 920-261-1947 scottangus47@gmail.com

48 Hardware Innovations Offer Better Solutions Highlighting examples of innovative new products and better solutions from some of the world’s top hardware companies.

A DV E R T ISI N G

54 Cabinet Concepts by Design Cabinet Vision automation enables shop to design, estimate, produce and track its high-end, custom residential cabinetry.

Ryan Wagner VP Sales & Marketing | Bedford Falls Communications 302 N. 3rd Street, Watertown, WI 53094 PH: 920-261-1945 rwagner@bedfordfallsmedia.com G R A P H I C D E SI G N — P R I N T P U B L I C AT I O N S

Karen Leno Graphic Designer | KML Design, Inc. kmldesign@mchsi.com C I R C U L AT I O N / SU B S C R I P T I O N S

440 Quadrangle Dr, Suite E, Bolingbrook, IL 60440 subscriptions@cds1976.com PH: 630-739-0900, option 1

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60 Countertops: Porcelain Makes a Move The strength of new gauged porcelain slabs paired with the limitless design possibilities available to porcelain is creating immense opportunity for suppliers in the countertop market.

& U N I T I N G M AT E R I A L S , T E C H N O L O G Y A N D D E S I G N

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news@bedfordfallsmedia.com ON THE COVER:

C O M P O S I T E PA N E L A S S O C I AT I O N MAIN OFFICE

19465 Deerfield Avenue, Suite 306 Leesburg, VA 20176 PH: 703-724-1128 FAX: 703-724-1588 Toll Free 1-866-4COMPOSITES www.CompositePanel.org CANADIAN OFFICE

Post Office Box 747, Station B Ottawa, Ontario CANADA K1P 5P8 PH: 613-232-6782 FAX: 703-724-1588 INTERNATIONAL TESTING AND CERTIFICATION CENTER

73 Lawson Road, Leesburg, VA 20175 PH: 703-724-1128 FAX: 703-724-1588 www.itcclab.org

TRANSFORMING SPACE TO THE MAX FINEST GAME TABLES FEATURE FINE SURFACES UNITY THROUGH DIVERSIFICATION AT ILCAM

Sculptures Jeux is a manufacturer of transformable wood tables, casegoods and shelving units that Resource Furniture imports from Italy.

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RIDING THE WAVE AT STEVENS INDUSTRIES HARDWARE INNOVATIONS OFFER BETTER SOLUTIONS COUNTERTOPS: PORCELAIN MAKES A MOVE

Surface & Panel is published quarterly by Bedford Falls Communications, Inc., 302 N. 3rd Street, Watertown, WI 53094, telephone 920-206-1766. John Aufderhaar, President, Christine Aufderhaar, CFO. All rights reserved. No part of this publication may be reproduced or transmitted in any form, electronic or mechanical without written permission from the publisher. Subscription policy: Individual subscriptions are available, without charge, to manufacturers who engage in panel processing, qualified service providers and suppliers. Publisher reserves the right to reject non-qualified subscribers. One year subscription to non-qualified individuals: U.S. $50, Canada/Mexico $75, all other countries $100, payable in U.S. funds. Single issues are $15, and must be prepaid. Bedford Falls Communications, Inc., does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. Printed in the U.S.A. Postmaster: Send address changes to Surface & Panel, 440 QUADRANGLE DR, STE E, BOLINGBROOK, IL 60440-3455. Please direct all subscription questions to: Surface & Panel, 440 QUADRANGLE DR, STE E, BOLINGBROOK, IL 60440-3455; or call: 630-739-0900 option 1; or e-mail: subscriptions@cds1976.com

The Digital Print Symposium HEADLINERS TUESDAY, AUG. 21. | ATLANTA, GA

Don Kuser GENERAL MANAGER | NORTH AMERICAN PLYWOOD CORPORATION

RON GILBOA

Rob Gilboa GROUP DIRECTOR | KEYPOINT INTELLIGENCE

With nearly 35 years of experience in graphic arts, publishing and industrial printing, Gilboa has a comprehensive view of the state of digital printing technology for decorative surfaceswhere it is, how it arrived and where it is going.

Mr. Gilboa spent the better part of a decade with Eastman Kodak Company where he served in executive marketing roles including: Vice President of Marketing at Kodak’s production inkjet group, Director of Worldwide Current Marketing & Operation, and Director of Worldwide Communications. He rejoined InfoTrends, a leading worldwide market research and strategic consulting company for digital imaging, in 2013. The brand has since combined forces with Buyers Lab, an allencompassing resource for digital imaging, to create Keypoint Intelligence.

If your company has an interest in digital printing, the application of digitally-printed decorative surfaces or how the industry is expanding to take advantage of this emerging technology—you’ll benefit from hearing what Mr. Gilboa has to say at the 2018 Digital Print Symposium at IWF Atlanta on Tuesday, Aug. 21.

For over 30 years Kuser has served as the General Manager of North American Plywood Corporation, a wholesaler of plywood and specialty value-added panels. The privately-held company has quietly grown its business for nearly 50 years, making bold investments in technologies that bely its relative size. In addition to panel-processing and PUR laminating capabilities, earlier this year North American Plywood finished installation of a new, large-scale UV coating line- including direct-digital staining/ digitalprinting capabilities.

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DON KUSER

The Digital Printing Symposium is produced by Keypoint Intelligence and Surface & Panel Magazine in conjunction with the International Woodworking Fair.

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“The Digital Print Symposium will reveal the world’s most advanced material, technology and design ideas.

It is a can’t miss event for anyone involved in producing or specifying surface designs and their applications.”

Other Presenters: Horst Schwesinger EXPORT MANAGER | BARBERAN

Stefan Bickert MANAGING DIRECTOR | BAUMER

Randy Paar MARKETING MANAGER | CANON

Register to attend the IWF 2018 Digital Print Symposium: registration.experientevent.com/ ShowIWF181 For more information about sponsoring the event, contact Ryan Wagner at ryan@bedfordfallsmedia.com.

Sponsors of the Event:

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The Digital Print Symposium is aimed at providing an educational platform for IWF attendees that are involved in the design, specification, and production of both laminates and direct decorated surfaces. The symposium will focus on digital printing opportunities available, as well as introduce attendees to leading manufacturers in the digital arena that provide printing, advances in software, and inspection technologies.

Decorative surfaces have long been a staple of the woodworking industry. They provide a cost-effective alternative to natural surfaces, and in many cases, provide a superior and durable surface in a range of applications from kitchen & bath, furniture, and architectural elements. Typically achieving quality décor layer relayed on traditional printing technologies.

These enabled high volume manufacturing a low cost per unit. Advancements in digital printing for décor paper, as well as direct surface printing, are now allowing for many improvements to the supply chain, productivity, and customization in order to meet customer needs for short– as well as long-run production. s&p

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Transforming Space TO THE MAX

R

Resource Furniture Has Become a Giant Among High-End, Multifunctional Furniture Retailers B Y

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on Barth is almost apologetic when he uses the term Murphy bed to describe the Clei multifunctional wall beds his company imports from Italy.

“The name Murphy bed has this connotation in the public’s mind of being something that is clunky and uncomfortable,” said Barth, co-owner of Resource Furniture, headquartered in New York. “The Clei system we started importing over 10 years ago was like 20 generations beyond what anybody has seen in terms of quality of the wall bed, design of the wall bed and the multifunctionality of the wall bed. It’s not this huge hulking presence in the room. It’s high-end Italian furniture.”

Clei wall beds are constructed with a combination of thermally fused laminate and honeycomb panels.

“Clei found a way to balance structural integrity and weight because in Europe these things are routinely carried up four or five flights of a 15th-century building,” Barth said. “These products are built to last.

“We have had 24 Clei bunk beds at the Princess Elisabeth Polar Research Station in Antarctica since 2009. They have been working in the harshest of environments without issue. The beds also hold up to the heat and humidity of Miami or Mexico City. I have never heard of any structural failures or problems of a panel delaminating.”

Clei wall beds are designed and manufactured in many sizes and configurations, including queen, twin and bunk beds. By day, they can pull double duty as sofas, shelves, home office desks or dining tables. Clei, pronounced clay, also manufactures modular closet systems and bookcases that integrate seamlessly with its

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wall beds to create cohesive, space-saving storage solutions.

“The Clei wall bed has a fully sprung base with a real mattress designed for a function and comfort for everyday use, not just as a guest bed,” Barth said. “A studio apartment in Manhattan with one of Clei’s wall bed/sofas, for example, becomes a living room. It’s like moving from a studio apartment into a one-bedroom apartment.

“Our thing is not small spaces,” Barth added with emphasis. “Our thing is efficiency of space. Yes, we do sell furniture to make small spaces more inhabitable, but at the same time our mission is focused on multifunctionality, hybrid use of any space. Micro apartments are a big part of our business, but so are condominiums, single-family houses and vacation homes that sleep 12.”

TRANSFORMING SPACES TRANSFORMS A BUSINESS

Just as Clei wall beds transform living spaces, becoming Clei’s exclusive North American dealer transformed Resource Furniture’s business model. The company has grown to become what the Wall Street Journal dubbed “the biggest retailer in the multifunctional space in the U.S.” Within the last decade, the New York City-based company has added dozens of space-saving, multipurpose furniture lines imported from Italy and other European Union countries. After expanding into more space-concept furnishing and accessories, Resource Furniture launched showrooms in Los Angeles, San Francisco, Washington, D.C., Mexico City and four Canadian cities.

“When my business partner, Steve Spett, and I founded Resource Furniture in 2000, we offered a catalog of furniture, stone, tile, hardware and other products from 406 Italian and other European CONTINUED ON PAGE 12 �

The Italian Connection

“Clei’s wall beds would be impossible to make without the high quality of today’s wood composite panels. You couldn’t get the rigidity and tolerances without it.”

RON BARTH, CO-OWNER OF RESOURCE FURNITURE

Ron Barth, co-owner of Resource Furniture, came well prepared to help spearhead his company’s main focus on importing high-end Italian furniture.

In the late 1980s, Barth worked for an Italian furniture company and lived in Italy for several years. Upon returning stateside, Barth spent nine years with the Pace Collection, a high-end contemporary furniture company of renown founded by twin brothers Irving and Leon Rosen. Again. Barth’s Italian savvy came in handy as the Rosens regularly attended the Milan Furniture Fair in search of new sources of products for the Pace Collection.

While directing the Pace Collection’s New York showroom, Barth worked with Steve Spett, CFO of Pace. Each of them left the company on separate terms, only to reunite to co-found Resource Furniture in 2000.

Founded to serve general contractors in and around New York City, Resource Furniture has evolved to focus on adaptable, multifunctional and high-quality furniture imported from Italy mostly and other European countries.

Resource Furniture is the exclusive North American distributor for Clei, an Italian manufacturer of multifunctional wall beds and other space-saving furniture.

A few of the other transformative furniture brands Resource Furniture imports from Italy include: • MOBILFORM, a manufacturer of custom closets featuring wood, glass or metal doors. The company also makes paneling and bedroom furniture. “Closets and storage are a big part of people’s lives, and they make beautiful products,” Barth said.

• ALTACOM, a manufacturer of tables that Barth said can transform from coffee tables to dining tables. “They are very innovative with materials in their use of things like cement finishes on panels, ceramics, slate veneer and stratified melamines. They always seem to be at the forefront of finishes,” Barth said.

• SCULPTURES JEUX, a manufacturer of transformable wood tables, casegoods and shelving units. The company’s products are characterized by a Nordic-looking style, simple and pure in their shapes and intersections of parts. n

PHOTOGRAPHY BY SHAWN HANNAH

CLEI WALL BEDS ARE DESIGNED AND MANUFACTURED IN MANY SIZES AND CONFIGURATIONS, INCLUDING QUEEN, TWIN AND BUNK BEDS. BY DAY, THEY CAN PULL DOUBLE DUTY AS SOFAS, SHELVES, HOME OFFICE DESKS OR DINING TABLES.

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manufacturers,” Barth said. “We were always looking for things that were different, visual and generally not available anywhere else in the U.S.” Clei wall beds filled that bill.

“We understood when we saw Clei’s product that it was revolutionary,” Barth said. “We saw this as a niche in the marketplace that was unfilled. The multifunctionality and quality of the furniture brought it into a different category for the high-end home.”

Barth said Spett and he knew they were onto something in 2006 after they outfitted an apartment for a single mother with four kids in the Urban Glass House designed by Philip Johnson.

“We did the apartment wall to wall with Clei wall beds, closets and shelving units. In a way, we took a 1,400-square-foot space and turned it into a five-bedroom apartment. Everything came perfect from the factory and installed without a problem. Steve and I looked at each other and said, ‘This is a business.’”

Resource Furniture ordered Clei samples to display and began advertising the products through local media. An ad in the New York Times elicited inquiries not only from homeowners in New York but from all over the country.

“There was a frenzied demand for it,” Barth said. “Once we realized there was a market for this furniture, we started adding other products like transforming consoles that extend into almost 10-foot dining tables, storage systems and home office systems.”

The financial crisis that triggered the Great Recession slowed but did not halt Resource Furniture’s momentum. Undeterred by the collapse of Lehman Brothers, Barth and Spett committed to renovating a fourth-floor space on Third Avenue for what is still its flagship showroom.

“We knew the timing was risky, but we were fortunate to not see 12

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a down year in 2008 or 2009, and then our sales started to explode again in 2010,” Barth said.

Despite the success Resource Furniture enjoyed selling Clei wall beds, including shipping products around the country, Barth said it was hard to find established furniture retailers willing to take on the line.

“Oddly enough, we found one dealer in Miami who has been quite successful, but there really was very little interest from other furniture retailers to carry this line of furniture,” Barth said. “They saw it as too complex, too expensive and too much work to deliver and assemble. They didn’t believe in the marketability of the product no matter what we told or showed them.”

Barth and Spett decided to take matters into their own hands.

They opened Resource Furniture’s Los Angeles showroom in 2012, quickly followed by new showrooms in San Francisco and Washington, D.C. In addition to Miami, Resource Furniture has forged exclusive agreements with retailers to sell Clei furniture in other cities including Chicago, San Diego and Portland, Oregon.

INSIDE CLEI’S FACTORY: ‘INCREDIBLE AUTOMATION’

Clei’s factory is a veritable working showroom of IMA Schelling technology, much of it installed within the last three years.

“The plant features incredible automation from vacuum lift loaders for sizing of panels to automated packaging of the completed components,” Barth said.

The progress of each part is tracked by a bar code system beginning as it exits the Schelling panel saw. The bar code label includes instructions for subsequent drilling, edgebanding and other operations.

In addition to a Schelling panel saw, the Clei factory has an IMA BIMA P980 CNC machining center that combines routing, edgebanding and drilling of custom parts in one compact machine; an IMA CONTINUED ON PAGE 14 �

WITNESS THE INDUSTRY’S LARGEST AND MOST EXCITING

INTRODUCTION OF COLORS + FINISHES AT IWF - BOOTH 1962

Come celebrate with us

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BIMA 310 CNC router; and a pair of IMA laser edgebanders that render a zero-joint edge of panel components.

“Thanks to the innovative laser edgebander, the application of the edge to the panel is carried out by laser-welding instead of glue, thus ensuring an environmentally-friendly process,” said Roberta Colombo, export manager of Clei. “During processing, the laser melts the polymer layer on the back of a co-extruded edgeband. Our clients appreciate the jointless union of edge and panel.”

“Clei’s wall beds would be impossible to make without the high quality of today’s wood composite panels,” Barth said. “You couldn’t get the rigidity and tolerances without it. All of Clei’s patented pistons and hardware that allow this furniture to be transformed is hidden inside 40mm panels. There’s not a lot of room for error. You have to be able to support the motion of the bed and the transitioning that goes on. And without today’s advanced panel processing technology, you wouldn’t be able to automate the process to make these products to order.”

MUSEUM EXHIBIT SHOWCASES NEXT GENERATION HOUSING

THE OPEN HOUSE, DESIGNED BY ARCHITECT PIERLUIGI COLOMBO, ONE OF THE OWNERS AND LEAD DESIGNER OF CLEI WALL BEDS, WAS ORGANIZED BY RESOURCE FURNITURE AND CLEI. IT IS PART OF THE HOUSING FOR A CHANGING AMERICA EXHIBIT AT THE NATIONAL BUILDING MUSEUM IN WASHINGTON, D.C.

Resource Furniture’s and Clei’s leadership in space economy is amply demonstrated in the Making Room: Housing for a Changing America exhibit making an extended run through Jan. 6, 2019, at the National Building Museum in Washington, D.C. With 30 percent of housing now lived in by one person and more people aging in place, the exhibit explores the challenges and opportunities for meeting under-served housing needs.

The star attraction of the Making Room exhibit is the Open House,

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mixology

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MIX & ENJOY.

CATCH US AT IWF

BOOTH #1748 14

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866-344-8132 | www.northerncontours.com

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a flexible 1,000-square-foot demonstration home that shows how flexible and hyper-efficient layout combined with transformable furnishings can maximize living space to accommodate a wide variety of lifestyle scenarios, including roommates, extended families and retirees. The Open House, designed by architect Pierluigi Colombo, one of the owners and lead designer of Clei wall beds, was organized by Resource Furniture and Clei.

In addition to Clei wall beds, storage units and transforming tables, the Open House features: • Motorized acoustical walls from Hufcor that fold open to convert two bedrooms into a living room.

• Closet systems by Capitol Closet Design with doors, drawer fronts and other components from Northern Contours.

• European-style kitchen cabinetry by Ernest Rust that incorporates Blumotion soft-close mechanisms, Blum Servo-Drive electric drawers and Häfele LED lighting.

• A height-adjustable kitchen counter with a built-in induction cooktop. A push of a button lowers the counter to serve as a dining table.

“I think the Making Room exhibit showcases a new typology of what can be done within 1,000 square feet,” Barth said. “This takes universal design to a new level and shows how one home using our furniture can be adapted to serve so many different demographics–families, singles, aging place–you name it in a highly functional and space-efficient way. I can imagine a big builder constructing 500 homes using this concept in a very affordable way.” s&p THERE HAVE BEEN 24 CLEI BUNK BEDS AT THE PRINCESS ELISABETH POLAR RESEARCH STATION IN ANTARCTICA SINCE 2009. THEY HAVE BEEN WORKING IN THE HARSHEST OF ENVIRONMENTS WITHOUT ISSUE.

Olon creates simplicity in sourcing with our one-stop-shop approach for architects, designers and builders requiring NEXGEN®, VelourTouch and custom components.

Our products are used in the kitchen & bath, closet, office furniture, hospitality, healthcare, educational and store fixture market segments.

Product offering:

Exciting new products will be available at IWF. Come visit us at Booth #1518

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nature would be flattered.

visit us at iwf atlanta 2018 booth 846 Feel great about your design and manufacturing choice. STEVENSWOODÂŽ merges environmentally sustainable materials that are 100% recycled and recovered, or GRN+ non-added formaldehyde core materials with resilient decorative surfaces to create panels that are environmentally friendly, luxoriously affordable and incredibly durable.

Discover our newest texture families: WALNUT PITTONI, MEZZO CHERRY and TRENTO OAK. Legno's true-realistic wood patterns and texturematched grains are the ideal complement for your designs. Request your free samples today.

(217) 857-7100 stevens-wood.com

World Leader in Surfacing Shares What’s Next in Residential Interiors

TIMOTHY J. O'BRIEN

Wilsonart Engineered Surfaces is among the world's leading manufacturers and distributors of innovative, high-performance surfaces. Wilsonart manufactures and distributes High Pressure Laminate, Quartz, Solid Surface, Coordinated TFL and Edgebanding, and other engineered surfaces for use in the office, education, healthcare, residential, hospitality and retail markets.

The company, headquartered in Austin, Texas, is continually evolving, improving and adding products to meet the surfacing needs of modern consumers. To learn what's new at Wilsonart and what's planned, Surface & Panel interviewed President and Chief Executive Officer Timothy J. O'Brien.

Q. What makes Wilsonart one of the world's most innovative surfacing companies?

A. Wilsonart is more than a laminate or quartz company. We are an engineered surfaces company. At Wilsonart, we offer multiple solutions for all your surfacing needs. This provides our customers with more than just great designs, but also the ability to choose the right design, the right texture, and the right performance, at a price that fits their budget.

We’re making fingerprint-resistant, water-resistant, scratch- and scuff-resistant, and soft-touch innovations the standard for surfacing products. Because we’re a company that believes a consumer's everyday life deserves luxury materials that work hard and are easy to maintain.

SLEEK CABINETS AND COUNTERTOPS FEATURE TRACELESS LAMINATE IN BLACK VELVET AND QUARTZ IN XCARET, RESPECTIVELY.

Q. Can you tell us about some of the surface innovations that are really taking off?

A. Here are four of the most exciting innovations developed by Wilsonart: • Traceless: This is our fingerprint-resistant laminate that was introduced at KBIS this year. Featuring a smooth and velvety feel, Traceless eliminates smears, smudges and streaks, making it perfect for high-touch areas such as cabinets and countertops.

• Textures: Aligned Texture is a first-of-its-kind technological breakthrough that synchronizes pattern and dimensional texture for a realistic woodgrain look; it is currently available in six oak designs. We’ll be rolling it out to other wood species in the future.

In addition, we just launched Soft Silk, which is a new ultramatte, true-to-stone finish.

• AEON Technology: This is a proprietary technology integrated directly into our Wilsonart HD and Premium Laminate products to ensure they perform with above-industry-average scratch- and scuff-resistance.

• RE-COVER: This is a quick-fix, peel and stick laminate product that can be adhered directly on top of existing laminate to immediately update a space.

Q. In your opinion, what's next in surfacing for residential interiors?

A. Surfaces are going beyond beautiful design and need to bring superior performance.

Material Mixology, the mixing and layering of materials, continues to grow in popularity for kitchen and baths because it allows consumers to be creative and blend their unique style preferences.

No other company can provide a mixed-material solution like Wilsonart Engineered Surfaces.

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WILSONART'S NEW THINSCAPE PERFORMANCE TOPS OFFER VERSATILTY AND DURABILITY IN AN ULTRA-THIN COUNTERTOP.

WILSONART COLLABORATED WITH DANNY SEO ON A COLLECTION OF DESIGNS THAT FEATURE "CRACKED ICE" PATTERNS INSPIRED BY NATURE.

With new designs launching every quarter, our Virtual Design Library offers more than 450 boutique design options.

Quartz is one of the hottest engineered surface materials on the market today. For the first time last quarter, according to Stone Update magazine, Quartz demand exceeded granite in the U.S. With advancements in design and manufacturing technology, we have been able to provide more natural stone-inspired looks that our customers gravitate towards.

Of course, we also have a variety of whites and marbles, which are still very popular. Solid Surface is also making a comeback as a nonporous surface available in designs that mimic natural stones.

Q. How important is it for Wilsonart to stay on top of residential trends?

A. It's imperative. We value what the market demands, and we pride ourselves on staying ahead of the trends through research, design councils, trendspotting trips, and most important, listening to our customers and designers from around the world.

Q. How is the company incorporating elements of these

We are also thrilled about a recent collaboration with designer, TV host and magazine editor Danny Seo, working on a collection of designs developed over the last two years that features “cracked ice” patterns. As Danny likes to put it, “Inspiration is everywhere in nature, and it seems glaciers are the last untapped design resources.”

We're also very excited to be expanding our distribution footprint for Solid Surface by opening our first state-of-the-art manufacturing plant here in Temple, Texas. The new plant will be more than 135,000 square feet, and will allow us to continue developing on-trend designs, along with some additional capabilities that will be announced later this year.

Q. How has Wilsonart transformed in the last 10 years?

A. Wilsonart has transformed from a U.S. High Pressure Laminate company to a global engineered surfaces company. Because we now offer Quartz, Solid Surface, TFL and other surfaces, we are working hard to become a trusted advisor when it comes to choosing which product is best for each and every customer. One thing that has not changed is our commitment to dependable, on-time service.

trends into its product offering?

A. A great example of this is our new Wilsonart THINSCAPE Performance Tops, which are versatile and highly durable, ultra-thin countertops. We have combined large-scale marble looks with softtouch finishes and an impact-resistant slim slab to create a beautiful high-performance product. Installers love it because it's easier to work with than porcelain options.

Q. Are there any exciting new projects in the works that Wilsonart will share with us soon?

A. In addition to the THINSCAPE Performance Top product, we are introducing a new Wet Wall solution in the U.S. This is an example of bringing a successful product from Europe to North America. Wet Wall allows us to put beautiful designs and performance into the bathroom.

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Finest Game Tables Feature Fine Surfaces 11 Ravens Specifies Chemetal, Treefrog B Y

S C O T T

W .

A N G U S

THE THESEUS SHUFFLEBOARD TABLE HAS A CHEMETAL BRUSHED ALUMINUM SURFACE.

11 Ravens makes some of the finest, most expensive game tables in the world. Not surprisingly, materials and style matter when you’re playing in such rarified air.

Take the Stealth table tennis table. Inspired by the Nighthawk stealth fighter aircraft, the table starts at $26,200 and can cost $70,000 and more when it includes materials such as aircraft grade aluminum, carbon fiber or acrylic. Or the Avetorre table tennis table, which starts at $25,400 and is available in several styles, including lime, orange with maple, orange with black and Lucite with leather.

Although all are stylish, not all of 11 Ravens’ tables are so exotic in materials and price. Among the company’s other go-to surfaces are brushed aluminum and brass from Chemetal and ebony veneer from Treefrog.

Founded in 2011 by a professional table tennis player and several dedicated advocates of the sport, 11 Ravens is the premier manufacturing company for custom-made game tables in the United States. Skilled artisans transform 11 Ravens’ sophisticated designs

AVETORRE TABLE TENNIS TABLE 20

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into handmade tables that often feature company and brand logos incorporated into the bases.

“We take great pride in our designs and the extreme care that goes into the construction of our tables,” said Michael Zaretsky, founder and CEO of 11 Ravens. “Each element is carefully handcrafted, sanded, polished and fitted by our skilled artisans.”

The standard table tennis table surface is a blend of proprietary, high quality composite materials designed to be scratch and damage resistant, as well as waterproof, he said.

11 Ravens’ limited edition, custom-made tables cost from $13,000 to above $50,000 depending on the complexity of design and materials.

Besides 14 different table tennis tables, the company sells tables for pool, billiards, shuffleboard, foosball, poker, blackjack and mahjong. It also offers game racks, chairs and dining tables.

Not surprisingly, the Stealth ping pong table and its lofty price have attracted considerable attention.

“Forrest Gump, a large section of China, and everyone who enjoys ping pong—sorry, table tennis—now knows what gaming perfection looks like. It looks like this,” wrote HiConsumption, a lifestyle magazine covering the latest in gadgets, architecture, design, fashion, art, vehicles and more.

All 11 Ravens tables can be made with Chemetal surfaces and Treefrog veneer among other surfaces. For example, the Trigon foosball table has a Chemetal Antique Brushed Brass Dark surface, while the Titan billiards table has a Chemetal Polished Smoked Aluminum base and a Brushed Pewter Aluminum apron. The Raven table tennis CONTINUED ON PAGE 22 �

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table has a Treefrog Madagascar Ebony Groove surface.

Zaretsky said the company chose Chemetal surfaces for their appearance and variety, among other reasons.

"When we discovered the Chemetal surfaces in the early days of the company, we were blown away by the variety of finishes they offered. It opened a new world for us aesthetically and helped us deliver the luxury modern products we always envisioned,” he said.

“Functionally, we love Chemetal for our clients because of their durability,” Zaretsky said. “Unlike a lacquer or even some veneers, Chemetal surfaces don't chip or crack.”

Chemetal is also one of the few companies to offer many of its surfaces in 4'-x-10' sheets, rather than just 4' x 8', and that was a big plus for 11 Ravens.

“Since all of our table tennis tables and most billiard tables come larger than 92 inches in length, Chemetal allows us to deliver the end product without seams,” he said. “From a manufacturing point of view, many Chemetal finishes come without phenolic backers, which result in cleaner joints."

As for Treefrog veneers, Zaretsky said the people at 11 Ravens are “huge fans” for two reasons: The veneers don’t crack, and they are consistent in design.

Other veneers were too thin and cracked when finished with a top coat, and sheets from the same type of tree were different.

“With Treefrog, we have the quality and consistency we expect of our clients,” Zaretsky said.

Geoff Schaefer, creative director and president of Chemetal/

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THE TITAN BILLIARDS TABLE HAS A CHEMETAL POLISHED SMOKED ALUMINUM BASE AND A BRUSHED PEWTER ALUMINUM APRON.

Treefrog/Interior Arts, said 11 Ravens’ tables are a great example of how design professionals use his company’s materials “to make cool stuff.”

“With over 200 metals designs, Chemetal is the ideal material to create so many different gaming table looks. Our materials are mostly thin, softer metals like aluminum, copper and brass, which are easier to bend and cut for skilled fabricators,” Schaefer said.

“Treefrog is a European quality prefinished veneer laminate. It’s luxurious and applies as easily as a laminate. It looks fantastic on 11 Ravens’ tables.” s&p

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Unity Through Diversification ILCAM Creates Strategic Internal Supply Chain To Become One of World’s Leading Door Makers

E

B Y

S U Z A N N E

ven if you haven’t heard of ILCAM, you’ve likely seen its products. ILCAM is the biggest supplier of wrapped five-piece doors to North America and the leading manufacturer of furniture frontals in the world, said Andrea Malisan, marketing and account manager.

“ILCAM exports 95 percent of its products,” Malisan said. “The main markets are Europe, which we consider our domestic market, and North America, though we have a market presence in nearly every country.”

ILCAM’s customer list reads like a who’s who of kitchen and contract furnishing manufacturers, including prestigious European houses such as the Symphony Group and Howdens Joinery in the UK, Nobilia of Germany, France’s Conforama and Kvik of Denmark.

Stateside, ILCAM’s innovative products can be found in the offerings of the country’s top kitchen cabinet manufacturers.

Headquartered in Cormòns Friuli Venezia Giulia in Italy’s northeastern-most region, ILCAM has a corporate culture that is innately “glocal.” Bucolic farmland and deep-rooted traditions shape the company’s strong work ethic and commitment to environmental, economic

V A N G I L D E R

and social sustainability.* The location welcomes global influences with a natural opening to the sea and major transport routes connecting central Europe, southern Europe and Slavic countries.

Founded by Tullio Zamò in 1959, ILCAM originally supplied legs and table stands to the local furniture industry. The company’s mission has grown: “To make homes a better place to live in, ‘dressing’ furniture with beautiful and well-made frontals through our heritage which benefits from Italian flair and craftsmanship.”

Today, Zamò’s sons—Pierluigi Zamò, current president, and Silvano Zamò, vice president—operate an empire. ILCAM’s vision is “to become the leading supplier of high quality furniture frontals, tailored to the needs of retailers, distributors, producers and manufacturers.” The company meets that goal by producing and delivering 70,000 pieces daily to a global customer base. It also boasts the broadest material offering in the sector.

PRODUCT MIX

ILCAM offers solid wood, wood-veneered and painted products, but most of its volume is made up of engineered materials—primarily rigid thermofoil along with flat-laminated, UV-cured curtain-coated panels and specialty products.

“Due to their versatility, quality, price point and design/engineering opportunities, PP, PVC and PET foils are highest in demand, then paper foils. ILCAM can combine all of these while maintaining the same design,” Malisan said.

To manage the complexity of materials and technologies, ILCAM developed a complete and flexible industrial system. Production is

FOUNDED BY TULLIO ZAMÒ IN 1959, ILCAM ORIGINALLY SUPPLIED LEGS AND TABLE STANDS TO THE LOCAL FURNITURE INDUSTRY. 24

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diversified through strategic business units that manage key technologies for the three major product categories: wood, foil and paint. Each unit is equipped with the most advanced technologies, automation, software tools and continually trained craftspeople.

Efficiencies are gained from the economies of vertical integration and application of Agile principles. ILCAM’s individual parts operate with an integrated manufacturing logic capable of combining multiple materials into virtually any end product. Projects converge at a centralized warehousing and logistics hub.

With 45 years of experience, business unit LICAR International specializes in profile wrapping, as well as wood veneer and decorative laminate veneer (DLV). It supplies five-piece doors assembled with different joints—shaker, cope, miter and French miter—as well as profile-wrapped parts, drawers and accessory moldings for the kitchen, bath and residential furniture markets.

“MDF is the most common composite panel used in wrapped products,” Malisan said. “Particleboard is used for slab components and when the quality of the final surface does not depend on the substrate.”

Business unit Lanta specializes in PVC-free flat-laminated doors and panels. Two facilities in Italy total 140,000 square feet and produce key brands Laminlac and Laminglass. Laminlac is a high-gloss or super-matte product made with a PET foil, coating and protective film. Laminglass is a high-gloss panel with the aesthetic of glass.

Across the eastern border in Slovenia, business unit ILMEST specializes in veneered wood doors and panels. Business unit ILROM,

TODAY'S MANUFACTURED PRODUCT FLOWS THROUGH ILCAM’S LOGISTICS HUB. OVER 300,000 SQUARE FEET OF COVERED WAREHOUSING IS PROVIDED BETWEEN TWO FACILITIES.

located close to forest resources in Romania, focuses on solid wood products.

ILCAM offers a curtain-coated UV-cured product available in a wide range of finish textures. Business unit TPS specializes in painted doors. To achieve the best surface quality for painting, white TFL on MDF is the most commonly used substrate.

Altogether, the capabilities of the business units allow ILCAM to offer a huge range of solutions customized in material, color, texture and construction.

“Preferences are always changing. In recent years, trends show a focus on matte finishes, but texture is not a selling driver on its own, just a part of fashion,” Malisan said. “As a group, we have developed CONTINUED ON PAGE 26 �

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the possibility to combine wrapping and laminating materials with textured TFL and coatings to meet changing demands.”

TARGETED MARKETS

ILCAM focusses on four target markets: kitchen cabinet manufacturers, furniture manufacturers, contract furnishing and component distributors.

Product development begins with a collaborative approach to the primary functions of sales and marketing.

“One of our skills is applying international experience to local fashion and lifestyle trends, with the added value of made-in-Italy flair. We work with the customer to find the best solution for its market,” Malisan said. “In North America over the last three years, we’ve seen increasing demand for five-piece doors. But at the same time, contemporary products like slab doors with the clean lines of European design play a leading role in frontal styling. Our strategy is to accompany customers to this direction.”

Across all market segments, ILCAM takes a co-marketing approach focused on serving customers through research and customization.

“Our sales are driven by problem-solving,” Malisan said. “We combine customer objectives with technical prowess to develop products that meet performance and compliance criteria.”

The strategy ensures products are engineered for the most efficient manufacturing processes to keep costs down and maximize speed to market.

CONTINUED ON PAGE28 �

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Innovative Super Matte a Favorite at ILCAM’s LICAR After conducting its own testing of super mattes, LICAR International arrived at a definite conclusion.

“SERICA is the best-performing super matte on the market,” said Carlo Bortolussi, product manager at LICAR, which is part of the ILCAM group. “As a result, it has been added to our stock line.”

SERICA, developed by ALFATHERM, is a significant advancement in super matte surface technology, providing the furniture industry with a cost-effective, paint-effect surface with multiple advantages, said Dustin Smith, commercial manager of Alfatherm North America.

Available in both PVC and PET, the UV-lacquered surface of SERICA offers an attractive finish with an extensive range of applications. It can be membrane pressed to achieve 3D doors, profile wrapped for five-piece doors or flat laminated for panel applications Due to its high scratch resistance, SERICA super matte eliminates the need for an added layer of protective masking, a process that is standard with other matte products, Smith said.

As such, acquisition costs are reduced, as is the overall scrap rate in production processes.

“Five-piece door production with SERICA can go through all production processes without the need of a protective masking, dramatically reducing our overall scrap rate,” LICAR’S Bortolussi said.

Further, Smith noted, SERICA’s innovative thermal healing properties allow for the easy repair of micro-scratches, increasing the lifecycle of the end product. A simple process restores its original silky finish.

Originally produced in PVC, SERICA is also available in PET, providing an environmentally friendly option. PET industrial waste can be recycled, thus reducing the overall ecological footprint of its production. n

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“Due to their versatility, quality, price point and design/engineering opportunities, PP, PVC and PET foils are highest in demand, then paper foils. ILCAM can combine all of these while maintaining the same design.”

ANDREA MALISAN, ILCAM'S MARKETING AND ACCOUNT MANAGER

Kitchen cabinet and furniture manufacturers benefit from ILCAM’s complete internal industrial chain. High production capacity and optimized processes are backed by advanced management and quality control systems, allowing ILCAM to reliably deliver the widest range of products in the industry. On the back end, ILCAM creates customized packaging design and labeling for customers. The company’s control of the distribution chain minimizes customer risk.

In service of contract furnishing, manufacturing flexibility makes it possible for ILCAM to efficiently provide prototyping and manage small volumes to meet requests for samples and mock-ups.

Experimental testing and sophisticated data processing are used to forecast demand, evaluate costs and calculate production times.

Additionally, the company has established relationships with accessories suppliers within a consolidated chain of subcontractors.

Production flexibility enables ILCAM to supply finished parts and panels or semi-finished products to components distributors, allowing customers to lower costs and add customization value by performing finishing processes in-house. The ability to integrate technologies and processes makes ILCAM a responsive distribution partner capable of meeting the most varied product demands. Simultaneously, ILCAM provides sound support in logistics and offers just-in-time production for certain products, reducing storage requirements for distributors and allowing for quick adaptation to market trends. The company’s inventory management system and warehousing services effectively provide solutions to some of the biggest channel issues distributors face.

* EIR (Embossing In Registration)

CONTINUED ON PAGE 30 �

J-Print Welcome to the other side of digital printing

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BRINGING PRODUCT TO MARKET

Manufactured product from each strategic business unit flows through ILCAM’s logistics hub. Over 300,000 square feet of covered warehousing is provided between two facilities.

Storing all the materials for the ILCAM group in one place streamlines the organization of full trucks. Fifteen container trucks move through the hub daily in a sophisticated cross-docking warehousing system that makes it possible to combine materials produced by different units on the same truck.

Over five decades, ILCAM has developed a complete internal industrial chain with integrated technologies. By leveraging high levels of specialization, economies of scale, production synergies and logistical solutions, ILCAM delivers furniture frontals made from leading-edge materials to the world.

“Our success does not come about by chance, but from shared values,” Malisan said. “At ILCAM, we continue to view the way we live as an ever-evolving process, in which function and emotion come together. We experiment with materials and colors to make endless, forward- thinking possibilities so our customers can free their imagination and create unique spaces.” s&p *Certifications KITCHEN CABINET AND FURNITURE MANUFACTURERS BENEFIT FROM ILCAM’S COMPLETE INTERNAL INDUSTRIAL CHAIN. HIGH PRODUCTION CAPACITY AND OPTIMIZED PROCESSES ARE BACKED BY ADVANCED MANAGEMENT AND QUALITY CONTROL SYSTEMS.

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ILCAM is ISO 9001-certified for quality, ISO 14001-certified for the environment, FSC and PEFC-certified to ensure the source of raw material from eco-sustainable cultivations. ILCAM has also implemented the health and safety management system according to the OHSAS 18001 standard.

Are You Ready for

CHANGE? Then Get Ready for the MT&D Symposium

PHOTO BY FR ANK I SHMAN

L TODD BRACHER

Leading the discussion at the second annual symposium will be powerhouse speakers Todd Bracher and Tom Wujec, both internationally known for spurring creative thought, envelopepushing innovation and strong market growth among their top-shelf business clients.

ike it or not, the only constant in today’s business world is change. Suppliers, distributors, manufacturers and designers must adapt or be left behind by competitors who see disruptions as opportunities.

Accordingly, change, disruption and the opportunities they bring will be key themes during the 2018 Material, Technology & Design Symposium @ CPA Fall Meeting, set for Sept. 23-25 in Nashville.

Leading the discussion at the second annual symposium will be powerhouse speakers Todd Bracher and Tom Wujec, both internationally known for spurring creative thought, envelope-pushing innovation and strong market growth among their top-shelf business clients.

Bracher is an acclaimed industrial designer who is founder and creative director of Todd Bracher Studio. As a design strategist, he has guided some of the world’s leading brands to realize differentiation through design, including 3M, Herman Miller, Humanscale and Cappellini.

“Our strategic design process helps our clients leverage their unique assets to achieve market growth, elevate brand visibility and evolve product portfolios for a contemporary audience,” Bracher said.

CONTINUED ON PAGE 34 �

TOM WUJEC 32

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Certified. Sustainable.

Eco-Certified Composites are Among the Greenest on Earth.

What are Eco-Certified Composites?

ECC stands for Eco-Certified™ Composite, as defined in the stringent ECC Sustainability Standard and Certification Program for composite panel products – specifically particleboard, MDF, hardboard and engineered wood siding and trim.

What makes a composite panel Eco-Certified?

Composite panels that carry the ECC mark are manufactured in facilities that are certified to meet the stringent requirements of the ECC Sustainability Standard.

ECC panel manufacturing facilities meet rigorous environmental requirements utilizing objective-based criteria and annual on-site audits. Each must ensure that its composite panels meet the stringent EPA TSCA Title VI and California Air Resources Board (CARB) formaldehyde emissions regulations AND achieve at least three of the following requirements:

• • • • •

Demonstrate a Carbon Footprint Offset Use Local Wood Fiber Resources Use Recycled/Recovered Wood Fiber Minimize Wood Waste in Manufacturing Hold a Valid Wood Sourcing Assessment or Certificate

What about LEED v4 Credit?

• MATERIALS AND RESOURCE (MR) CREDIT: Building Product Disclosure Optimization – Environmental Product Declaration • MR CREDIT: Building Product Disclosure Optimization – Sourcing of Raw Materials • MR CREDIT: Building Product Disclosure Optimization – Material Ingredients

Who sponsors ECC Certification?

The Composite Panel Association (CPA) developed the ECC Sustainability Standard, including its pioneering Carbon Calculator. CPA administers the ECC Certification Program in North America as a third party certification agency accredited to ISO/IEC 17065 by the American National Standards Institute (ANSI).

• MR CREDIT: Furniture and Medical Furnishings • INDOOR ENVIRONMENTAL QUALITY (EQ) CREDIT: Low-emitting materials

www.ECCproduct.org The Composite Panel Association is committed to advancing and certifying the sustainability of industry products for residential, commercial and industrial uses.

sandpsymposium.com

THE 2018 SYMPOSIUM WILL BE AT THE BRAND-NEW JW MARRIOTT IN DOWNTOWN NASHVILLE, ADJACENT TO THE MUSIC CITY CENTER AND JUST STEPS FROM THE BARS AND RESTAURANTS OF LOWER BROADWAY. � CONTINUED FROM PAGE 32

Bracher is recognized as the pre-eminent voice in American product design. He has more than 75 products on the market and two dozen patents and has won numerous global design awards, including being named a Top 100 Global Design Influencer by Wallpaper magazine and a two-time International Designer of the Year.

Bracher designs products with the intent to offer his clients a competitive advantage in the marketplace. His designs are aesthetically pleasing, but he also considers business objectives, contemporary culture and human needs to create products that help businesses evolve and grow.

Wujec is chief disruptor at Autodesk—the Oscar-winning industry leader in 3D computer animation technology and one of the world’s largest software companies—and he revels in sharing today’s exciting

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opportunities during his celebrated talks on innovation.

Wujec has worked with a diverse range of clients, from the largest automotive and consumer product manufacturers to visual effects and gaming companies. In his talks, he explores why innovation matters, why it is a vital engine of economic growth and how to foster it within any organization—from plucky startups to billion-dollar legacy companies.

Working closely with Fortune 100 companies, he is counted on to create innovation practices at all stages, from strategic planning to design and implementation. Now—and with his latest book, The Future of Making—he brings his vision of disruptive innovation to global audiences, demonstrating how the entire process of imagining, iterating, constructing, manufacturing, distributing and selling products has changed in unprecedented ways.

The symposium is a high-powered, must-attend event that brings together leaders of the composite panel and decorative surfaces industries, along with users and specifiers of those products. For the second year, the symposium is being co-sponsored by Surface & Panel magazine and the Composite Panel Association in conjunction with CPA’s Fall Meeting.

Among attendees are CEOS, architects, cabinet makers, component suppliers, distributors, furniture manufacturers, industry suppliers, interior designers, store fixture manufacturers and students.

“The event provides a unique opportunity for companies that use composite wood to network and learn from each other and from our CPA members, who represent the very best panel producers and surfacing companies in North America.” said Jackson Morrill, president of CPA. Besides top speakers such as Bracher, Wujec and trailblazers in the industry, the symposium features an exhibit hall with dozens of companies displaying innovative products ranging from the latest in textured composite panels to creative new surface materials and components.

“We at Surface & Panel are passionate about panel processing and providing a platform for this remarkably dynamic industry to highlight the latest and greatest in all facets of the business–from technology to design to application,” Publisher John Aufderhaar said.

The 2018 symposium will be at the brand-new JW Marriott in downtown Nashville, adjacent to the Music City Center and just steps from the bars and restaurants of Lower Broadway.

For more information on the Material, Technology & Design Symposium—including registration and room reservations—go to sandpsymposium.com. s&p

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AFFILIATE SPOTLIGHT:

NORTH AMERICAN BUILDING DISTRIBUTION ASSOCIATION We want to honor the North American Building Material Distribution Association (NBMDA), a trade association representing wholesale distributors of surfacing materials, wood panels, cabinet hardware, finishes and other related products.

NBMDA was founded in 1952 as the National Building Material Distributor Association in Chicago, Illinois to meet the needs of distributors in the building materials space. After consolidating with the Canadian National Building Material Distributors Association (CNBMDA) in 1994, the association made the shift to being known professionally as NBMDA. Each year, NBMDA partners with the North American Association of Floor Covering Distributors (NAFCD) to put on their annual convention. The event, which launched in 2010, is

one of the most highly anticipated in the industry and gathers over 800 distribution professionals from the US and Canada’s top flooring and building distribution companies.

NBMDA is also committed to education within the building material distribution industry. In 1987, NBMDA launched their Education Foundation, which provides funding to support the industry’s need for additional training at any timber company, timber facility or other organizations. NBMDA’s Education Foundation continues to develop modern and cost-effective educational solutions to support workers throughout North America. In addition, it is a sponsoring association of the University of Innovative Distribution, an educational program that has been serving the supply chain for 25 years by focusing on the unique needs of the wholesale distribution industry.

In addition to providing education for the entire industry, NBMDA also places an emphasis on educating its members. In 2017, NBMDA deepened their partnership with The Cleveland Research Institute to provide in-depth research reports through the NBMDA Research Center. These research reports, which cover such topics as residential homebuilding updates, digital advertising/e-commerce trends and transportation insights and trends, are exclusive to members and aim to provide them with the information they need to take their businesses to the next level.

Timber Products Company is a proud member of the North American Building Material Distribution Association and appreciates the value this incredible organization brings to the building materials distribution and timber industries.

HOW TO MITIGATE IMPACTS OF THE NW LOG PRICE SURGE What do forest fires, mountain pine beetles, the U.S. housing market and China all have in common? Each one has pushed price of northwest timber ever-closer to record levels.

It’s a classic story of supply and demand.

In Canada and on the U.S. west coast, pine beetles and last year’s wildfires devastated timberlands, while mills in Florida and Georgia were paralyzed by Hurricane Irma resulting in a limited timber supply. Transportation issues, including a shortage of trucks and railcars, further limited buyer access to available timber.

All the while, the world’s appetite for softwood timber continues to grow.

Domestic lumber consumption remains high due to new home construction, and at the same time demand from China and other Asian countries remains strong.

can no longer remain profitable, the market will be forced to adapt.”

As a result, prices for Douglas fir rose to $700/Manufactured Board Feet (MBF) last year and shows no signs of dropping.

A 2018 article from Forest2Market notes, “High log prices are great for the region, but only if the market will bear the same high costs through the entire supply chain and to market. When raw material costs become so expensive that manufacturers

Work with a VerticallyIntegrated Partner

With that in mind, here are two ways to mitigate the impact of the recent softwood price surge:

Here at Timber Products Company, we offer wood product solutions. By working directly with customers, we help them save money and get a product engineered to their exact specifications.

timberproducts.com

THE CLOSET CONNECTION Here at Timber Products Company, we produce all grades of particle board substrates to fit our customers’ needs including shelving, kitchen cabinets, closets and door core.

At our particle board facility in Medford, Ore, door core and sheet stock are key competencies. Eric Poppe, our Particle Board Production Superintendent in Medford shares his insights: “When you create particle board, it’s not as simple as slamming the press shut, cooking it for four minutes, then opening it up. The press changes the properties of that wood momentarily.

There are chemical reactions with the resin, and you’re converting the moisture in the board to steam, driving it into the core,” Poppe said.

“Getting the right moisture content really matters. Believe it or not, you want your face moisture to be different than your core moisture content.”

Our door core is the superior choice for both exterior and interior doors. In • Depending on the facility, we provide state-of-the-art manufacturing and offer lay-ups, sanding, custom cuts, custom components, laminating and finishing.

• Our partner TP Trucking has more than 150 owned or owner-operated trucks.

TP Trucking is always on-time and operated by safe, professional drivers.

Don’t Focus Only on Price

As any good salesperson knows, the price is only one factor in a buyer’s decision. A “good deal” can quickly turn into a massive liability when a product does not arrive on time or if it fails to meet the client’s expectations.

We have built a reputation for highquality hardwood and softwood plywood, hardwood and softwood veneers, hardwood lumber, particle board and a wide variety of decorative overlays to

addition to offering a better surface for sanding, our door core is speciallyengineered for excellent machinability and screw-holding strength.

We Welcome Custom Size Requests

“Some companies say if it’s not a truckload quantity, we’re not interested in the order. We’re not that way. We specialize in working with customers to make sure they get what they need, even if it’s multiple different cuts on different loads,” Poppe said.

Poppe further explained, “We use an optimizer that allows us to maximize our press. We take the master sheets and cut them into an almost infinite number of custom sizes. Our fl exibility to get customers what they need is a big plus for us and of course, the quality keeps them coming back.”

Creating Eco-Friendly Particle Board We

utilize

recovered

fiber

from

suit different needs and design trends.

As an added value, all our products are created with the environment in mind.

We are committed to environmental sustainability and we can prove it.

hardwood plywood and softwood plywood manufacturing facilities to make our particle board. “Nearly all of our raw material is someone else’s waste,” explained Poppe.

“We use various types of discarded wood fiber from lumber, plywood and engineered wood products—both our own and from external sources,” Poppe said. “We get the material in either hogged up, chipped up or chewed up form. We sort it, mill it if it needs to

be milled and dry it if it needs to be dried. Then we put it on a mat, press it together and make a product out of it,” Poppe said.

All Timber Products Company particle board is made from 100% postindustrial recycled/recovered fiber and is available in many thicknesses, widths and lengths. To learn more, download our particle board product brochure, or contact one of our friendly product experts.

KEEP UP ON OUR BLOG To read more about the latest industry news, trends and events visit: timberproducts.com/blog

We also engineer softwood plywood panels to meet the unique needs of each customer—saving time and money. Our manufacturing facilities can produce panels up to five feet wide, ten feet long and 1-15/32 inches thick with optional plug and touch sanding, full sanding or tongue-and-groove.

Let us know how we can help you find a quality product at a price that fits your budget. Give us a call at 1-800-557-5131 or connect with a Timber Products wood and panel expert via our website. Smaller orders can be handled by one of our trusted wholesale distributors. Locate an authorized Timber Products Company distributor near you.

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@TimberProducts

facebook.com/timberproducts

youtube.com/TimberProductsTV

RIDING THE WAVE B Y

S C O T T

W .

S

A N G U S

Onshoring, Versatility, TFL Growth Help Generate Surge at Stevens Industries

tevens Industries has done an impressive job of building its business since it started as a small wood shop in Teutopolis, Illinois, in the 1950s.

From humble beginnings as a residential cabinet supplier, Stevens has grown to become the largest manufacturer of commercial casework and architectural millwork in the United States. It also recognized a tactical opportunity in 1979 and became one of the United States’ first producers of thermally fused laminate, then known as melamine.

While Stevens remains smart and aggressive in pursuing new opportunities in its core area of manufacturing casework for education and health care, it has seen a twist in the last few years. Business is coming to Stevens in increasing amounts from companies seeking strategic manufacturing partners, including many that previously looked overseas for help.

“In many instances, we don’t know the full backstory as to why they sought us,” said Todd Wegman, president of Stevens. “We just know there are more opportunities now, and they would have been talking to overseas manufacturers in the past.”

Without a doubt, Stevens’ versatility and reputation as a quality casework manufacturer and supplier of increasingly innovative TFL panels have played key roles in attracting the new business, which began showing up several years ago but continues to ramp up significantly, Wegman said.

“In many cases, it’s been positive word of mouth. They called us.”

The recent surge is the latest chapter in a story that began when Charles “Chuck” Stevens moved from Chicago to Teutopolis in 1956 and started making wood products in his father-in-law’s two-car garage. The company quickly established a reputation for its highquality and forward-thinking kitchens, but Stevens recognized the potential of commercial work in the 1960s and began producing furniture, cabinets and equipment for education.

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TODD WEGMAN

Stevens Industries FOUNDED:

1956

NOTABLE:

LOCATION:

Teutopolis, Illinois

• Consumes 1 million square feet of board per week

Furniture and casework for education and health care; TFL panels; modular casework; early education furniture.

PRIMARY PRODUCTS:

EMPLOYEES:

580

ANNUAL SALES:

$116 million

950 cabinets per day; 6,000 TFL panels per day PRODUCTION:

EQUIPMENT:

60 CNC machines; 6 presses

SPACE: 650,000 square feet of manufacturing and warehouse space

HALL B, BOOTH 4528

• Yearly board purchases would cover 970 football fields.

• Produces a quarter-mile of countertops per day • $10 million in capital improvements over the last 12 months • 100 percent employee owned – Employee Stock Ownership Program (ESOP) • 25 percent of employees have 15 years or more with company.

Wegman tells the story of how the transition to education components and commercial work, to some degree, was boosted by a true-to-life elevator pitch. It happened at the old Louisville Woodworking Show, where a Stevens representative rolled a sample cabinet onto an elevator and started a conversation with two men who sold school cabinets. The meeting continued in the bar, and the result was a relationship that benefitted all involved and continued for decades.

Tom Wegman joined Stevens in the 1970s, with Tom Wegman taking a crucial role of general manager and head of engineering. Together, the two saw the emergence of laminated materials and made the bold and expensive move to convert the company’s production, materials and equipment to a panel-based system that would set the course for decades of growth. After buying TFL from Canada, they decided in 1979 to invest in their own panel press but immediately realized that the company needed only about 20 percent of the equipment’s capacity. Stevens Industries began offering its panels to other customers, and another branch of the business was born.

“Some of our biggest successes were people who were using low basis weight papers and struggling with them, and then there was a certain amount of people using HPL,” Wegman said. “We invested in thermofused to be our own vertically integrated supplier, but the rest of the market decided this was a good idea and jumped into our customer base.”

The stage for Stevens’ current expansion as a manufacturing partner was set in the 1990s when it began handling overflow capacity for other companies, but it wasn’t the best-case scenario for Stevens, Wegman said.

CONTINUED ON PAGE 40 � STEVENS RECOGNIZED THE POTENTIAL OF COMMERCIAL WORK IN THE 1960S AND BEGAN PRODUCING FURNITURE, CABINETS AND EQUIPMENT FOR EDUCATION.

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Q3 2018

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STEVENS HAS GROWN TO BECOME THE LARGEST MANUFACTURER OF COMMERCIAL CASEWORK AND ARCHITECTURAL MILLWORK IN THE UNITED STATES, SERVING A VARIETY OF MARKETS, INCLUDING HEALTH CARE.

“When our customers of raw materials would run out of capacity, we would make their products for them. We were always at the ready to use our equipment to help our panel customer base.”

The problem was that during inevitable market recessions and seasonal down cycles, Stevens would lose that work, making it difficult to plan and grow, Wegman said. So Stevens developed a new strategy to become an ongoing partner for those companies in what it calls its “private label business.”

“They can rely on us year in and year out, and they don’t have to invest in their own equipment and building. They can use their core competencies of design and marketing to get their product to market,” Wegman said. “It turned things around for us when we could become a strategic partner for them in the manufacturing and not just a place to turn for overflow production.”

While allowing those companies to focus on their core competencies, Stevens offers a vertically integrated company that can cover manufacturing from the production of panels to the assembly of products. It’s a win-win.

“We have the supply right next to the fabrication, which is right next to the assembly,” Wegman said.

What do these strategic partners look like? Among the top traits, besides needing manufacturing support, is that they are introducing TFL as one of their surfacing solutions, Wegman said.

“I could name closet companies that have been traditionally wire shelving or office companies that have been veneer or HPL or kitchen and bath companies that have been in low basis CONTINUED ON PAGE 42 �

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Protecting the environment, one panel at a time.

Cowhorn Vineyard & Gardens Photo: Claire Thorington Design Builder: Green Hammer

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weight paper. The common thread is they want to introduce thermally fused laminate into their products.”

While TFL was once seen mostly as a lower-cost product, it’s now viewed as a design feature because of the incredible improvements in recent years, Wegman said, noting particularly the advent of deep textures, embossed in register development and matte surfaces.

Stevens got into texturing panels about eight years ago after noticing that TFL was much better accepted in Europe than in the U.S., likely because of the textures and other features available overseas, he said.

“We had to get past the standard look of what standard TFL was and make it more appealing to the end customer. As we caught onto that and started introducing texture, more realism and working with printers and treaters to bring that realism to the market, it had people using other surfaces wanting to learn more about it.”

Among companies that contract with Stevens to manufacture products, about 60 percent use Stevens’ TFL, while the rest require that it be bought from other suppliers. For its part, Stevens works hard to make it “very easy” for customers to use its TFL, Wegman said, citing significantly reduced leads times for panels produced on site.

Stevens is far from just a TFL-based company, though. It produces HPL, solid surface and acrylic, for example, and buys metals, stainless steel, veneers and stone surfaces when needed.

“We’ve always been a company through the commercial casework business that uses multiple materials,” Wegman said. “I believe that’s one of the reasons that companies come to us. If you look at one of the products that we produce, it has options all over the place. You can buy any surface for the chassis and any surface for the top or bottom or the countertop.

“There is huge vertical integration that uses a tremendous CONTINUED ON PAGE 44 �

moisture resistance.

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material mix to give designers the freedom to choose what they like.”

Stevens knows that some of its partners probably could buy their own equipment and do the manufacturing themselves. Apart from the cost barriers that stand in the way, Stevens believes its versatility, quality and dependability help keep those customers in the fold, Wegman said.

As for the trend of companies to onshore their manufacturing with Stevens, Wegman is happy to have the work regardless of the reasons.

“In the past, a company—a strong product development, a strong marketing company—they’re going to do their make-buy decision, and their make decision was at their facility and their buy decision was going to be overseas. They weren’t even including U.S.—or North American-based manufacturing.

“Now we view they are looking for quicker lead times, flexible operations, effective operations and people who can give them some design flexibility and not give up on price. And they are seeing they can get that from the states now.”

To some degree, Stevens acts as a venture capital arm of the partners for which it does manufacturing, Wegman said.

“Instead of them investing in equipment and space, they invest their efforts in the design and marketing. We invest our efforts in manufacturing. We work together to bring that product to the market.”

Stevens recognizes that its competition isn’t resting, especially on the TFL side. U.S. board capacity is increasing rapidly as several foreign-based companies ramp up their production in big new domestic facilities. In Teutopolis, the goal is to grow the overall pie

STEVENS INDUSTRIES IS 100 PERCENT EMPLOYEE OWNED. TWENTY-FIVE PERCENT OF EMPLOYEES HAVE 15 YEARS OR MORE WITH THE COMPANY.

CONTINUED ON PAGE 46 �

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for TFL sales while protecting the size of Stevens’ slice, Wegman said.

“Our job is help grow the acceptance of TFL, and in reality we have used the motto around here that it’s our job to kill wood.”

Wegman acknowledged that Stevens hasn’t marketed itself as well as it could. But in light of the recent demand, the company is working on that.

“It ended up being spread largely by word of mouth that we were a solution for our customers’ manufacturing needs, or perhaps we were producing their panels, and they asked: ‘Can you do more?’

Nearly every one of the companies that we are working with is pushing us to put together a corporate abilities marketing piece so they can see what we can do, and we’re in the middle of doing that.” s&p

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Hardware Innovations OFFER BETTER SOLUTIONS According to the dictionary, “innovation” can be defined simply as a new idea, device or method. Typically, however, innovation also is viewed as the application of better solutions that meet the needs of today’s market. Better solutions? Those are definitely what hardware companies have in mind when they research, develop and introduce their innovative new products. Here are some of the best examples of those new products and better solutions from some of the world’s top hardware companies:

� SALICE Silentia+: The new-generation of soft-close hinges Silentia+ allows a perfect and constant soft closing of a door in any condition, use and application. This innovative soft-close technology guarantees excellent performances to the complete range of hinges. Silentia+ includes numerous technological elements in the required spaces and maintains the aesthetics of the hinges of the first generation. n

� HÄFELE Ixconnect Tab 15 Shelf Connector Save time on products with the Häfele Ixconnect Tab 15 Shelf Connector. Tools won’t be necessary. With a drill hole diameter of only 15 mm, the Tab 15 is simply pressed into the shelf manually, delivering a sturdy, reliable connection.

Ideal for quick relocating of shelves, the connector can be installed and easily moved without causing damage. It is available for shelves with thickness of 16-19 mm. n

CONTINUED ON PAGE 50 �

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(R)EVOLUTION

( ) ( ) saliceamerica.com

Silentia+ The new-generation of soft close hinges from Salice.

Besides showing no resistance while opening doors, the Silentia+ hinges guarantee an exceptional and consistent deceleration thanks to twin fluid dampers, delivering a perfect soft closing action in all applications and under any temperature condition.

Silentia+ incorporates an innovative switch to adjust the deceleration mechanism. This enables the closing speed of doors of any size or shape to be perfectly adjusted.

10°

+

30°

HAR DWAR E

2018

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BLUM � LEGRABOX Offering the right solution for every level of user convenience is important, and Blum understands the need to keep the product range manageable. With the new LEGRABOX profile, cabinet manufacturers can offer a larger scope of function, all with one runner, saving warehouse space and confusion when ordering parts. Three different motion technologies, BLUMOTION, TIP-ON BLUMOTION and SERVO-DRIVE, are all achievable with the optimized LEGRABOX profile. Whether you opt for the electric or mechanical opening support system, Blum’s various motion technologies give you the right solution for every living area and every comfort level.

Getting the right mix: Combining different motion technologies in the same space brings enhanced user convenience to kitchens and other areas of the home.

The integrated BLUMOTION soft close ensures drawers always close softly and effortlessly. Cabinets equipped with the SERVO-DRIVE electrical motion support system glide open at a single touch, which is especially handy for waste drawers. TIP-ON BLUMOTION is Blum’s mechanical solution, allowing cabinet drawers to open with a single touch and close gently with a fluid push. LEGRABOX can be customized with these features. n

� FEDERAL BRACE Atlas Floating Vanity Support Crafted specifically with strength, performance, and lifelong endurance in mind, Federal Brace’s Atlas Floating Vanity Support can withstand a load of 1500 pounds, offering a level of stability previously unheard of. The increased point load capacity and sleek, minimalistic design of this brace make it an excellent option for high-traffic spaces, such as hotels, restaurants and other commercial facilities. n

CONTINUED ON PAGE 52 � 50

surfaceandpanel.com

MAXCESS ACCESS WITHOUT EXCESS

MAXCESS by Grass tips the scales of physics by offering a “Less is More” approach to full access cabinetry. In fact, less is MUCH more. More access to the drawer interior with less of the traditional drawer slide and more of the modern features you want; Soft-close, 75 lb weight rating, and minimal extension loss. Get more without accepting less. MAXCESS.

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HAR DWAR E

2018

� CONTINUED FROM PAGE 50

�

GRASS

Kinvaro D and Tiomos Flap Drop-down Flap System Grass America is pleased to introduce our new “upside down” flap system. The Kinvaro D, the newest member of the Kinvaro lifter family, is a stylish, modern dropdown flap system that creates a minimalistic look with clean lines while offering easy access into the cabinet contents.

The Kinvaro D offers the perfect drop-down flap solution for the classic wall cabinet. Functional and comfortable, the Kinvaro D offers an integrated damping system, providing a gentle opening that rests at 90° with the assistance of the Tiomos Flap hinge.

Kinvaro D-M flap system is offered in White, Night and Smoke with a flap door weight capacity up to 22.5 pounds. The Kinvaro D-S is offered in White and Night with a flap door weight capacity up to 13.5 pounds.

Both systems integrate nicely into various types of cabinetry and can be mounted left or right, vertically or horizontally with a minimum cabinet depth of 82mm (3 1/4”).

The sleek and modern Tiomos Flap Hinge is a flat rectangular hinge that offers a 90° opening angle and three-dimensional adjustment. When a handle-free door application is preferred, Tiomos Flap can be paired with the Tiomos Tipmatic pin system.

Kinvaro D and Tiomos Flap hinge are the perfect combination for a fold down system that ensures the open flap is flush with the base panel every time. n

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�

TITUS CABINET HARDWARE Titus New Generation Hinge T-type

The Titus T-type hinge delivers superior features that save time during cabinet assembly and provide consistent performance on a wide range of doors.

The “3Way” snap-on mounting plate allows intuitive hinge-to-plate mounting in three directions, improving and simplifying the mounting experience. The innovative T-type hinge provides easy installation of tall cabinet and pantry doors even where four or five hinges are required.

Its shallow hinge cup allows installation of a wide range of cabinet doors, accommodating material from 15mm to 26mm thick.

A durable design ensures reliable operation over a wide range of tolerances, even in the case of accidental misalignment and inaccurate drillings. An easily accessible adjustment button provides intuitive adjustment of the dampener, which gives an efficient soft closing performance on doors of varying size and weight. n

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1-800-547-9520 â&#x20AC;˘ www.timberproducts.com

Design, Estimate, Produce, Track Cabinet Concepts By Design Uses Cabinet Vision Automation to Create High-End Custom Cabinets

N

ot every married couple is suited for business partnership, but dream team Shelley and Matt Wehner found the entrepreneurial freedom they both craved in opening Cabinet Concepts by Design.

“We wanted to be in control of our own destiny, and we weren’t going to be able to do that by working for other people,” said Shelley Wehner, co-owner, designer and project manager at the Springfield, Missouribased shop. “Matt and I are completely opposite in how we approach situations, so we combine our strengths to accomplish goals.”

Ten years after the pair took over, the sleepy shop that they bought with no work in the pipeline has expanded to six times its initial size and employs a staff that’s grown from six to 30.

About 90 percent of the shop’s business is residential, and a glance at the company’s website is proof that quality and creativity in design are high on its list of priorities. While Cabinet Concepts by Design offers custom cabinetry for any wish list, featured kitchen designs include products in lodge, old world, traditional, farm house, transitional, light and airy, rustic, and contemporary styles. The company also offers storage solutions for closets, garages, pantries, and other spaces.

Shelley was always interested in interior design, and Matt, who studied math in college, had long been a woodworking hobbyist. Initially, the plan was for Shelley—a then stay-at-home mom to the couple’s three children—to manage the shop’s books. Matt, with help from four employees,

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would handle sales, design and production. However, it quickly became apparent that Shelley was naturally suited to design and that handling the business side was a better fit for Matt.

“After year three, we were working so hard and still weren’t really making any money, but we had an excellent reputation, and I felt in my heart that we had something great,” Shelley said. “We hired a business advisor who told us to make small, continuous improvements, and by year five, the business totally flipped.”

In year five, the Wehners bought a larger shop, and the business grew from 5,000 square feet—in which they were bursting at the seams—to 30,000 square feet. The new workspace meant more opportunity, as well as bigger and better equipment.

That series of continuous improvements also led to the comprehensive implementation of the Cabinet Vision Screen-to-Machine (S2M) solution, by Vero Software, as part of the shop’s daily process. While the previous business owners had purchased an older version of the system, they didn’t take full advantage of the solution’s capabilities.

“Everything used to be manual, and then we just slowly upgraded,” she said. “We started with an old dinosaur, a point-to-point router, and old CNC software. Once we kind

AGED ASH

WEATHERED ASH

CONTINUED ON PAGE 58 �

954.420.9553 56

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of figured that out, we realized it was more efficient, but it was older technology.”

Today, the Wehners and their team use nine seats of Cabinet Vision S2M to create designs and generate the g-code needed to go from art to part. Due to the combined power of software and machinery, the shop is now completing a greater number of operations in less time, and with fewer errors.

“The thing with us is that with the Cabinet Vision and CNC router,

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it takes a lot of the human error out of the cutting process,” Shelley said. “Now, as long as the piece of plywood is mounted on the CNC properly, almost anyone would be able to run the machine without a significant amount of training. It eliminates operations and simplifies the process.”

Projects typically begin when designers meet with clients to identify their needs and desires, as well as to determine the scope of projects and other vital details. To begin a design in Cabinet Vision, designers enter the dimensions of the room in which the finished project will be installed, followed by the project dimensions and other details.

At Cabinet Concepts by Design, initial designs are then passed on to the shop’s estimator, who uses Cabinet Vision to determine production costs and supply an estimate. “We take the information that Cabinet Vision spits out to do our bids,” she said.

The shop uses the software as an integral part of its business, from design and estimation to cutting, production management and project tracking. The ability to generate high-quality, 3D renderings in the software is also a helpful sales tool, as it enables clients to better envision the final product.

“Clients really appreciate seeing the drawings. When they describe what they want to us, they sometimes want us to do things that we know are not possible,” Shelley said. “When they can see it in 3D, it makes sense, and it helps them to see why something will or won’t work.”

By the time a job in Cabinet Vision is sent to the shop floor, staff have access to material lists, cut lists and assembly sheets automatically generated by the software.

To further increase automation, Cabinet Concepts by Design also uses Cabinet Vision User Created Standards (UCS), which is a customizable automation tool that can be easily applied to any job to increase efficiency and enforce company standards. For example, if a Cabinet Vision user prefers a certain construction method for a particular type of material, the software will automatically apply a UCS for that method when the material is used.

The company also uses Cabinet Vision’s nesting capability, which maximizes material and reduces error. For select jobs, the shop uses the solution’s batching function, which facilitates the batching of similar jobs for even greater material yield.

For easy job identification and tracking, Cabinet Concepts by Design uses the solution’s barcode labeling system, which reduces error and makes it easier to track cut parts throughout the shop.

“I honestly couldn’t do this job without Cabinet Vision,” Shelley said.

“It really helps someone who doesn’t have a cabinet background to be successful in this industry.” s&p

Get inspired by our new design trends and visit us, August 22 - 25, 2018 at the International Woodworking Fair in Atlanta, GA â&#x20AC;&#x201C; Building C, Exhibit Hall Level, Booth #2046. info@schattdecor.us | www.schattdecor.com

Countertops:

PORCELAIN MAKES A MOVE B Y

C A R O L I N E

C

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W E E K L Y

oming into 2018, many tile suppliers cited countertops as a key opportunity for the year ahead. According to Glenn Harry, general manager, stone and sales operation for Mohawk’s Dal-Tile Corporation, the U.S. countertop industry is estimated to be about $5 billion in sales annually, with roughly half coming from stone, quartz and a newer product known as gauged porcelain. While the sector is still in its early stages in the U.S., it’s definitely growing, and many suppliers are pointing to gauged porcelain tile—which the U.S. has recently started to embrace—as the reason.

While porcelain slab size increased almost five years ago, the slabs were too thin to be used on countertops without substantial reinforcement. More recently, porcelain slab thickness increased from 3mm to 12mm, with some products measuring up to ½-inch thick. The strength of these new gauged porcelain slabs paired with the limitless design possibilities available to porcelain is creating immense opportunity for suppliers in the countertop market.

Currently, the countertop market is dominated by quartz and natural stone, but Evan Nussbaum, vice president of product sourcing and training for Stone Source, predicts that’s about to change.

“The technical properties of porcelain make the surface undeniably appealing for the countertop market … that can compete directly with quartz, which had taken over most of the market share from granite in the last 20 years,” said Nussbaum.

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And James Amendola, director of sales and marketing at Sapienstone, a porcelain countertop brand within the Fiandre group, agreed, stating that the main driver behind the expanding countertop market is “an increasing number of companies are introducing porcelain materials for countertops.”

Paulo Pereira, MSI’s senior merchant of porcelain product, explained that gauged porcelain is perfect for countertops because it has all the same properties as traditional porcelain tile—strength, stain resistance, ease of maintenance and stability. “Product training will play an important part in how fast the fabricators will adopt the porcelain slabs,” he added.

And moving forward, many suppliers believe installation will play a key role in the sector’s success. The product itself, being thin — and easier to carry into the installation area—yet resilient, lends itself to installation better than quartz or stone. However, Nussbaum added that there is still quite a bit of outreach and education needed. “But each day sees more traction than the day before, and it is only a matter of time before porcelain takes over more share in the countertop space,” he said.

SAPIENSTONE BY FLANDRE

DESIGNS THAT SELL

In terms of design, the countertop sector is seeing trends similar to tile, but now with porcelain coming to play the possibilities are skyrocketing.

Quartz and granite are leading the design sector of the market, but one of the benefits of gauged porcelain is that it can be CONTINUED ON PAGE 62 �

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Q3 2018

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customized to emulate any look the consumer wants. According to Vance Hunsucker, national sales manager for ceramic tile and stone with Shaw, “There’s no limit to the colors or visuals it can take on.”

Roy Viana, product director at Dal-Tile, said that natural quartzite is trending right now and marble visuals are making a resurgence.

“Both consumers and architects and designers are looking for countertop solutions with superior aesthetics, including the beauty and depth of details of real marble and real stone, as well as higher durability and more competitive pricing,” said Fiandre’s Amendola.

Porcelain slabs also offer much more flexibility in aesthetics, as inkjet technology allows manufacturers to emulate the look the consumer desires, whether it’s a more natural motif or an intricate design.

According to Frank Douglas, vice president of business development at Crossville, natural stone visuals are, of course, always popular, but real stone can be rare and expensive, as well as impractical to use.

“Now … it’s possible to have the stone look you want and the performance your countertops require,” said Douglas. “For example, real Carrara marble is tender and prone to staining, while tile panels offer the realistic appearance in a material that will stand up to use for the long term.”

Some customers are even opting to put porcelain slabs over their existing countertops, and these new [porcelain] slabs can also be incorporated into other areas of the kitchen to produce a design theme, Shaw’s Hunsucker said. Porcelain backsplashes, cabinet end caps and flooring can be printed to match.

The printing process used to manufacture gauged porcelain also results in a “cleaner” visual because there are fewer seams, Hunsucker added.

NEED-TO-KNOW

According to tile manufacturers, one of the most important pieces of information retailers will want to know coming into the countertop market is the difference between natural stone and porcelain options.

Vance Hunsucker, national sales manager for ceramic tile and stone at Shaw, cited a variety of differences between the two options including the fact that porcelain is resistant to heat, easier to clean and does not need to be sealed. “It is 30 percent stronger than granite and other materials, and it resists chipping, cracking and scratching,” he said. “Porcelain’s longevity may offer customers a cost savings over time. Porcelain can be customized to emulate any look the consumer wants.”

Stone Source’s Evan Nussbaum, vice president of product sourcing and training, agreed, adding that consumers need to know there is a new alternative to quartz for countertops that is coming into the market in a big way.

“Retailers will want to align themselves with distributors and fabricators who can supply quality and service, and who are already familiar with working the material,” said Nussbaum.

In the end, Frank Douglas, Crossville’s vice president of business development, pointed to education as the key to success for today’s retailers looking to find opportunity in the countertop business.

“They need to have the information to guide specifiers to make the right choices for the aesthetic and performance requirements of the projects at hand — including exterior installations,” said Douglas.

“Tile panels are excellent for outdoor kitchen countertops, for example. Also, they need a fundamental understanding of how installation is managed to assure decision makers about the process as well as the product.” s&p Reprinted with the permission of Floor Covering Weekly— Feb. 26, 2018, pages 6 and 8

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F R O M

T H E

E D I T O R

The Cool Factor: Just LOOK At This Stuff I must admit that sometimes it’s hard to convince my friends that panel processing can be incredibly interesting. Even exciting. They’ll ask me to explain again what I’m doing these days and what exactly Surface & Panel covers.

I’ll give them a basic summary, and then the question inevitably comes: And that’s interesting?

Heck yes, I’ll say, and I’ll proceed to explain how cool today’s panels can be and how the new textures and finishes make TFL, HPL, 3DL and the other materials beautiful, realistic and func-

“I’ll proceed to explain how cool today’s panels can be and how the new textures and finishes make TFL, HPL, 3DL and the other materials beautiful, realistic and functional as all get out.”

tional as all get out. And how panel processing is huge in Europe and has been for decades. Now, it’s North America’s turn, I’ll continue, and the growth in production and use of panels is reflecting that relatively newfound acceptance on this side of the pond.

The next time the question comes up, though, I’m going to forgo the speech and simply hand my friend a copy of this issue of Surface & Panel. The cool factor comes through in spades.

I can’t talk cool without starting with 11 Ravens and its off-the-charts awesome game tables.

Yes, they are expensive, but each and every one is such a statement that I can see folks of means deciding they must have one for their bar or game room. And some of the most eye-popping tables contain Chemetal brass and aluminum surfaces and Treefrog veneers, all on composite panels. My story on 11 Ravens begins on page 20.

A little closer to mainstream, though still innovative and so cool, is the furniture from Europe that Resource Furniture sells in the United States. Much of it is “transforming” and space-saving furniture that maximizes the limited space in today’s popular small houses and apartments.

Resource seeks out the best and most interesting, much of it Clei furniture from Italy, and then makes it available here. Rich Christianson’s story on Resource starts on page 10.

Speaking of Europe, we’ve also got a feature on Italy’s ILCAM, Europe’s leading manufacturer of cabinet doors and drawer fronts. ILCAM’s vision involves new ways of thinking, planning, working and living, and it works to give value at all levels through design research, technological innovation and continuous improvement while focusing on the environment, as well as economic and social sustainability. Suzanne VanGilder’s story on ILCAM begins on page 24.

As if that’s not enough, I’ve got two words that put this issue over the top: cracked ice. That’s how Wilsonart describes the inspiration for a new collection of designs that emerged from a collaboration with designer, TV host and magazine editor Danny Seo. In a Q&A starting on page 36, Wilsonart CEO and President Timothy J. O’Brien details what’s next for residential interiors, including the glacial-inspired patterns.

Lastly, Stevens Industries has so much cool stuff going on with its manufacturing and panel business that the 580-employee company in Teutopolis, Illinois, is attracting “strategic partners” who previously would have looked overseas for production help. In my story starting on page 38, President Todd Wegman maintains that the staggering improvements in TFL’s designs and textures have played a critical role in helping bring that business on board at Stevens.

Very cool.

Scott W. Angus | Editorial Director | scottangus47@gmail.com

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A D V E R T I S E R S PAGE

PAGE

Alfatherm 5 908.301.0600 www.alfatherm.it

Kings Mountain International 41 704.739.4227 www.kmiinc.net

aacc

American Adhesive Coatings LLC 61 978.688.7400 AMERICAN ADHESIVE COATINGS COMPANY www.aacchotmelts.com

North American Plywood Corporation 11 800.759.6606 www.naply.com

Arclin 63 877.689.9145 www.arclinTFL.com

Northern Contours 14 866.344.8132 www.northerncontours.com

Biesse 31 877.824.3773 www.biesseamerica.com

Boise Cascade 67 888.264.7372 www.bc.com

Button Fix 27 +44 (0)20 8150 7190 www.button-fix.com Cefla 28 704.598.0020 www.ceflafinishing.com Chemisol 46 1.39.0331.523.351 www.chemisol.it Collins 42 800.329.1219 www.collinsco.com

Columbia Forest Products 7 800.637.1609 www.cfpwood.com

Composite Panel Association 33 866.4Composites www.ECCproduct.org

Daubert Chemical Company, Inc. 55 866.368.3983 www.daubertchemical.com Decotone 21 908.301.0600 www.decotonesurfaces.com

Olon 16 800.387.2319 www.olon.com

Panel Processing 23 800.433.7142 www.panel.com

Premier Eurocase 68 303.373.9718 www.premiereurocase.com Rehau 29 800.247.9445 www.rehau.com/us-en Renolit 47 +1.973.706.6912 www.renolit.com Riken 34 248.513.3511 www.riken-usa.com Roseburg 35 800.245.1115 www.roseburg.com Salice 49 800.222.9652 www.saliceamerica.com Sappi 9 207.856.4000 www.sappirelease.com Schattdecor 59 800.600.6100 www.schattdecor.com

Smartech 39 704.362.1922 Doelken www.smartechonline.com 57 905.759.1074

Stevens Industries www.na.doellken.com 17 217.857.7100 DVUV www.stevens-wood.com 58 216.741.5511

Stiles Machinery, Inc. www.dvuv.com 45 616.698.7500 www.stilesmachinery.com

Element Designs 26 877.332.3396

Synergy Thermal Foils www.element-designs.com 56 954.420.9553

Genesis Products 30 877.266.8292 www.genesisproductsinc.com Grass 51 336.996.4041 www.grassusa.com

www.synergythermofoils.com

Tafisa Canada 25 877.882.3472 www.tafisa.ca

Timber Products Company 36/53 800.547.9520 www.timberproducts.com

Hexion Toppan 43 888.443.9466 15 770.957.6447 www.hexion.com www.tia.toppan.com IMEAS Uniboard 65 678.364.1900 13 844.302.8585 www.imeas.net www.uniboard.com

Interprint, Inc.

Union Tool Corporation 2 413.443.4733 40 574.267.3211 www.interprint.com www.uniontoolcorp.com

King Plastic 22 800.780.5502 www.kingplastic.com 66

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Vortex 44 800.355.7708 www.vortextool.com

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sales@premiereurocase.com

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303.373.9718

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